Lincoln Electric IM581 manual

OPERA T OR’S MANU AL S AE400 WELD’N AIR - DC ARC WELDING PO WER SOURCE AND 35 CFM AIR COMPRESSOR IM581 February , 2000 F or use with machines having Code Number 10362 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation [...]

FOR ENGINE powered equipment. 1.a. T ur n the engine off bef ore troubleshooting and maintenance wor k unless the maintenance work requires it to be running. ____________________________________________________ 1.b . Oper ate engines in open, well-v entilated areas or vent the engine e xhaust fumes outdoors. ________________________________________[...]

ii SAFETY ii ARC RA YS can b urn. 4.a. Use a shield with the proper filter and cov er plates to protect your e yes from sparks and the ra ys of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b . Use suitab le clothing made from durab le flame-resistant mater ial to protect y[...]

iii SAFETY iii FOR ELECTRICALL Y powered equipment. 8.a. T ur n off input power using the disconnect switch at the fuse bo x before working on the equipment. 8.b . Install equipment in accordance with the U .S. National Electrical Code, all local codes and the manuf acturer’ s recommendations. 8.c. Ground the equipment in accordance with the U .S[...]

iv SAFETY iv W ARNING Assure that tank and compressor relief valves w ork pr operly , and are at correct pressure settings. NEVER move compressor with pressure in tank. DO NO T modify or repair air tank.[...]

v SAFETY v[...]

vi SAFETY vi SAE400 WELD’N AIR PRÉCA UTIONS DE SÛRETÉ P our v otre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce man uel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté P our Soudage A L ’Arc 1. Protegez-vous contre la secousse éle[...]

SAE400 WELD’N AIR Thank Y ou f or selecting a QU ALITY product by Lincoln Electric. We want y ou to take pride in operating this Lincoln Electric Company product ••• as much pride as we ha ve in bringing this product to you! Read this Operator s Man ual completely bef ore attempting to use this equipment. Sav e this manual and k eep it hand[...]

viii T ABLE OF CONTENTS SAE400 WELD’N AIR viii P age Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Installation Precautions . . . . . . . . . . [...]

A-1 INST ALLA TION SAE400 WELD’N AIR A-1 TECHNICAL SPECIFICA TIONS - SAE400 WELD’N AIR Make/Model Description Speed (RPM) Displacement Starting Capacities System P er kins 4 cylinder High Idle 1800 236 cu. in 12VDC batteries Fuel: 22.5 gal. 4.236 Diesel 63 HP @ Low Idle 1100 (3.87 L) (2 ) & Star ter 85.1 L Engine 1725 RPM Full Load 1725 Bor[...]

A-2 INST ALLA TION SAE400 WELD’N AIR A-2 Read this entire installation section bef ore you start installation. SAFETY PRECA UTIONS Do not attempt to use this equipment until y ou hav e thoroughly read all operating and maintenance man- uals supplied with your machine . The y include impor- tant saf ety precautions, detailed engine star ting, oper[...]

A-3 INST ALLA TION SAE400 WELD’N AIR A-3 HIGH AL TITUDE OPERA TION At higher altitudes, output der ating may be necessary . As a rule of thumb , derate the welder output 5% f or e ver y 500 meters (1640 ft.) abov e 1000 meters (3280 ft.). Contact a P er kins Ser vice Representativ e for an y engine adjustments that ma y be required f or high alti[...]

A-4 INST ALLA TION A-4 SAE400 WELD’N AIR ENGINE COOLING SYSTEM The cooling system has been filled at the f actor y with a 50-50 mixture of eth ylene glycol antifreeze and water . Chec k the radiator le vel and add a 50-50 solu- tion as needed. (See Engine Manual or antifreeze con- tainer f or alter nate antifreeze recommendation.) B A TTER Y CONN[...]

A-5 INST ALLA TION SAE400 WELD’N AIR A-5 WELDING OUTPUT CABLES With the engine off , connect the electrode and work cab les to the studs pro vided. These connections should be check ed periodically and tightened if neces- sar y . Listed in T able A.1 are copper cab le sizes recom- mended f or the rated current and duty cycle. Lengths stipulated a[...]

B-1 OPERA TION B-1 GENERAL DESCRIPTION The SAE400 WELD’N AIR is a diesel engine driven w elding po wer source. The machine uses a DC gen- er ator f or DC stick electrode w elding and an A C exciter f or 115/230 V A C auxiliary power . As a gener ator it can supply up to 3,000 watts of 115/230 v olt A C pow er . As a welder it pro vides up to 575 [...]

B-2 OPERA TION B-2 DESIGN FEA TURES AND AD V ANT A GES FOR STICK WELDING • Excellent DC constant current output f or stic k weld- ing applications. • Contin uous adjustment of both v oltage and current f or unsur passed welds on demanding jobs. • Remote control capability standard. FOR A UXILIAR Y PO WER • 3,000 watts of 115/230 V A C , 60 [...]

B-3 OPERA TION B-3 ENGINE CONTR OLS IGNITION SWITCH When placed in the “ON” position, this s witch energizes the fuel solenoid. When placed in the “OFF” position, the flow of fuel to the injection pump is stopped to shut do wn the engine . SPEED CONTROL LEVER Man ually allo ws the engine to run at its high idle speed controlled by the go ve[...]

B-4 OPERA TION B-4 Ho w to Set the Contr ols Assume you w ant a nor mal soft arc and about 135 amps , using a 5/32” (4.0 mm) electrode: 1. Set the “Job Selector” at the center of the b lack range . 2. Set the “Current Control” to read 135 amps on the blac k dial. 3. Star t to weld. 4. If you w ant a little more current, turn the “Job Se[...]

B-5 OPERA TION B-5 ENGINE OPERA TION Do not adjust the high idle engine speed (r pm) abov e the f actor y setting specification as this will ov erspeed the air compressor and v oid it’ s warr anty . ------------------------------------------------------------------------ ST ARTING INSTR UCTIONS Be sure all Pre-Operation Maintenance has been per- [...]

C-1 A CCESSORIES C-1 K799 Hi-Freq™ - Provides high frequency plus a gas v alv e f or TIG welding. A water valv e is av ailable as an option. Requires 115 v olt AC input. (Limited to 250A - 60% Duty Cycle). K802-C P ower Plug Kit - Kit includes male plugs for each auxiliar y receptacle. K805-1 Ether Start Kit - Injects ether for star ting aid. Rec[...]

D-1 MAINTENANCE D-1 ELECTRIC SHOCK can kill. ● Do not touch electricall y live par ts such as output terminals or inter- nal wiring ENGINE EXHA UST can kill. ● Use in open, well ventilated areas or vent exhaust outside MO VING P AR TS can injure . ● Do not operate with doors open or guards off ● Stop engine before servicing ● Keep a way f[...]

D-2 MAINTENANCE D-2 BEARING MAINTENANCE This welder is equipped with a doub le-shielded ball bearing ha ving sufficient g rease to last indefinitely under nor mal ser- vice. Where the w elder is used constantly or in excessiv ely dir ty locations, it ma y be necessary to add one-half ounce of g rease per y ear . A pad of grease one inch wide, one i[...]

E-1 TR OUBLESHOO TING E-1 SAE400 WELD’N AIR If f or any reason y ou do not understand the test procedures or are unab le to perf orm the tests/repairs saf ely , contact your Local Lincoln A uthorized Field Service Facility for technical troub leshooting assistance bef ore you proceed. CA UTION F or Air Compressor trouble shooting see the air comp[...]

E-2 TR OUBLESHOO TING E-2 SAE400 WELD’N AIR Obser v e all Safety Guidelines detailed throughout this man ual If f or any reason y ou do not understand the test procedures or are unab le to perf orm the tests/repairs saf ely , contact your Local Lincoln A uthorized Field Service Facility for technical troub leshooting assistance bef ore you procee[...]

E-3 TR OUBLESHOO TING E-3 SAE400 WELD’N AIR Obser v e all Safety Guidelines detailed throughout this man ual If f or any reason y ou do not understand the test procedures or are unab le to perf orm the tests/repairs saf ely , contact your Local Lincoln A uthorized Field Service Facility for technical troub leshooting assistance bef ore you procee[...]

E-4 TR OUBLESHOO TING E-4 SAE400 WELD’N AIR Obser v e all Safety Guidelines detailed throughout this man ual If f or any reason y ou do not understand the test procedures or are unab le to perf orm the tests/repairs saf ely , contact your Local Lincoln A uthorized Field Service Facility for technical troub leshooting assistance bef ore you procee[...]

E-5 TR OUBLESHOO TING E-5 SAE400 WELD’N AIR Obser v e all Safety Guidelines detailed throughout this man ual If f or any reason y ou do not understand the test procedures or are unab le to perf orm the tests/repairs saf ely , contact your Local Lincoln A uthorized Field Service Facility for technical troub leshooting assistance bef ore you procee[...]

F-1 WIRING DIA GRAMS SAE400 WELD’N AIR F-1 COLOR CODE RINGS FLASHING DIODE - (+) 1 3 TO ALT. EXC. TERMINAL ROTOR B AC AND RESISTOR AC B-BLACK G-GREEN N-BROWN R-RED U-BLUE W-WHITE Y-YELLOW ALTERNATOR SLIP ELECTRODE TO WORK BACK VIEW OF POLARITY SWITCH 5 4 1 B Y POLARITY SWITCH NOTE: CB1, CB2, CB3 & CB4 - RATED 15A, 250V POS C-RW CONTROL WIRING[...]

SAE400 WELD’N AIR F-2 WIRING DIA GRAMS F-2 M18777 ENGINE WIRING DIAGRAM - SAE-400 WELD’N AIR from moving parts, and insure all guards or covers are replaced after servicing. DAILY CHECKS: - Electrode and work connections are tight. - Rotate the current control twice to clean contacts. - All equipment in serviceable condition. AS REQUIRED: - Blo[...]

SAE400 WELD’N AIR F-3 DIMENSION PRINT F-3 18.50 22.14 22.00 27.12 24.50 8.12 3.00 .88 43.75 63.06 39.69 50.13 28.00 32.87 6.00 81.25 69.75 77.00 39.38 44.50 8.90 83.00 * = .81 DIA HOLES = .69 DIA HOLES * * CENTER OF GRAVITY WITH OIL AND WATER IN ENGINE, BUT NO FUEL. A M8869-33[...]

No w A vailab le ...12th Edition The Pr ocedure Handbook of Arc W elding With ov er 500,000 copies of pre vious editions published since 1933, the Procedure Handbook is considered by man y to be the “Bible” of the arc welding industry . This printing will go fast so don’t dela y . Place your order now using the coupon belo w . The hardbound b[...]

SAE400 WELD’N AIR W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German P ortuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL[...]

SAE400 WELD’N AIR W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German P ortuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhau[...]

• Sales and Ser vice through Subsidiaries and Distributors Worldwide • Cle veland, Ohio 44117-1199 U .S.A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .lincolnelectr ic.com • W or ld's Leader in W elding and Cutting Products •[...]